Waste to energy system and process for solid waste feedstock

ABSTRACT

A waste conversion apparatus and a method of implementing the apparatus are provided. The apparatus includes a control system, and a feedstock analysis system or output analysis system. A plasma forming device within a reactor of the waste conversion apparatus is controlled by the control system to apply a plasma arc to a supply of waste feedstock supplied to the system. Integrated feedback control is provided to the plasma forming device based on an analysis by the feedback analysis system to characterize of the supply of waste feedstock, and/or an analysis by the output analysis system to characterize a gas product from the reactor.

FIELD OF THE DISCLOSURE

The present disclosure relates generally to systems for extractinguseful resources from solid waste material. In particular, thedisclosure relates to a waste conversion apparatus and a method ofimplementing said apparatus.

BACKGROUND OF THE DISCLOSURE

The plasma processing of carbonaceous materials such as municipal solidwaste (MSW) is known, and has been proposed as a means for eliminatinglarge volumes of accumulated materials stored in urban and suburbanlandfills. The use of plasma torches provides advantages overincinerators or other combustion processes because the intense heatgenerated by the plasma torch (e.g., up to about ten thousand of degreesFahrenheit) dissociates the waste material, causing the organiccomponents of the waste to be turned to gas, and causing the inorganiccomponents of the waste to be converted to a relatively small volume ofinert vitrified material without combustion or incineration. The gaseousoutput is either filtered and collected or discharged, while thevitrified material is often used as an aggregate material amenable to avariety of construction uses.

Plasma processing has been suggested for use in processing bulkquantities of municipal solid waste (or similar types of waste), wherethe composition of the waste is significantly non-uniform. Currentplasma-gasification processes and similar technologies are limited inthese applications, as there are no large-scale installations that havebeen implemented where the varying compositions of the solid waste areanalyzed and characterized “on the fly” while the plasma process isongoing.

Furthermore, the use of mixed fixed/moving bed plasma reactors in pilotplants with continuous waste feed mode or batch mode is known in theart. However, the temperature control in these types of reactors is notcomplete, especially with increasing the size of the reactor. Also, thereactor must heat up before waste feeding, and this takes a long timeand consumes more electric power, which reduces the efficiency of theconversion process.

Thus there is a need for a plasma gasification system that can beeffectively employed for the large scale plasma processing of solidwaste. The system should be flexible enough to enable the use of avariety of feed-stocks, including MSW, biomass, municipal solid wastematerial, hazardous waste material, coal of varying grades, pulp andpaper waste material, wood products, sewage and sewage sludge material,food waste material, plant matter, rice straw material, and agriculturaland animal waste material.

SUMMARY OF THE DISCLOSURE

According to an aspect, there is provided an apparatus for plasma-basedconversion of solid waste feedstock into hydrocarbon gaseous products.The apparatus includes a reactor vessel, a continuous feed-in unit, anda control system. The reactor vessel defines a reactor chamber includingan inlet, at least one plasma forming device for generating a plasma arcwithin the reactor chamber and an outlet conduit for expelling at leastone gaseous product from the reactor chamber. The continuous feed-inunit is positioned for feeding a supply of solid waste feedstock to theinlet of the reactor chamber. The control system is connected to the atleast one plasma forming device of the reactor vessel, and includes atleast one processor programmed with computer executable instructions forcontrolling the at least one plasma forming device, based at least onthe composition of hydrocarbon-containing materials in the sample ofsolid waste feedstock, to apply heat at a target temperature profile,for a target time interval, to the supply of solid-waste feedstock toform the at least one gaseous product.

According to another aspect, there is provided an apparatus forplasma-based conversion of solid waste feedstock into hydrocarbongaseous products using closed-loop control. The apparatus includes areactor vessel, a continuous feed-in unit, a feedstock analysis system,and a control system. The reactor vessel defines a reactor chamberincluding an inlet, at least one plasma forming device for generating aplasma arc within the reactor chamber and an outlet conduit forexpelling at least one gaseous product from the reactor chamber. Thecontinuous feed-in unit is positioned for feeding a supply of solidwaste feedstock to the inlet of the reactor chamber. The feedstockanalysis system is positioned to collect and analyze a sample from thesupply of solid waste feedstock fed along the continuous feed-in unit.The feedstock analysis system includes at least one physicochemicalsensor for detecting at least one physicochemical characteristic of thesample of solid waste feedstock, and at least one spectral sensor fordetecting at least one spectral characteristic of the sample of solidwaste feedstock. The control system is connected to the feedstockanalysis system and to the at least one plasma forming device of thereactor vessel, and includes at least one processor programmed withcomputer executable instructions to:

characterize a composition of hydrocarbon-containing materials in thesample of solid waste feedstock based at least on the at least onephysicochemical characteristic and at least one spectral characteristicdetected by the feedstock analysis system; and

control the at least one plasma forming device, based at least on thecomposition of hydrocarbon-containing materials in the sample of solidwaste feedstock, to apply heat at a target temperature profile, for atarget time interval, to the supply of solid-waste feedstock to form theat least one gaseous product.

According to another aspect, there is provided an apparatus forplasma-based conversion of solid waste feedstock into hydrocarbongaseous products. The apparatus includes a reactor vessel, a continuousfeed-in unit, a feedstock analysis system, and a control system. Thereactor vessel defines a reactor chamber including an inlet, at leastone plasma forming device for generating a plasma arc therewithin, andan outlet conduit for expelling at least one gaseous product therefrom.The continuous feed-in unit is positioned for feeding a supply of solidwaste feedstock to the inlet of the reactor chamber. The supply of solidwaste feedstock includes a first feedstock portion and a secondfeedstock portion. The feedstock analysis system is positioned tocollect and analyze respective first and second samples from the firstand second feedstock portions. The feedstock analysis system includes atleast one physicochemical sensor element for detecting at least onephysicochemical characteristic of the first and second samples, and atleast one spectral sensor element for detecting at least one spectralcharacteristic of the first and second samples. The control system isconnected to the feedstock analysis system and the at least one plasmaforming device, and includes at least one processor programmed withcomputer executable instructions to:

characterize a composition of hydrocarbon-containing materials in thefirst sample of solid waste feedstock based on the at least onephysicochemical characteristic and at least one spectral characteristicof the first sample of solid waste feedstock;

control the at least one plasma forming device, based at least on thecomposition of hydrocarbon-containing materials in the first sample ofsolid waste feedstock, to apply heat at a target temperature profile,for a target time interval, to the supply of solid-waste feedstock toform a first one of the at least one gaseous product;

characterize a composition of hydrocarbon-containing materials in thesecond sample of solid waste feedstock based on the at least onephysicochemical characteristic and at least one spectral characteristicof the second sample of solid waste feedstock; and

adjust the at least one plasma forming device, based at least on thecomposition of hydrocarbon-containing materials in the second sample ofsolid waste feedstock, to apply heat at a second temperature profile,for a second time interval, to the supply of solid-waste feedstock toform a second one of the at least one gaseous product, at least one ofthe second temperature profile and second time interval being different,respectively, from the first temperature profile or the first timeinterval.

According to yet another aspect, there is provided an apparatus forplasma-based conversion of solid waste feedstock into hydrocarbongaseous products. The apparatus includes a reactor vessel, a continuousfeed-in unit, an output analysis system, and a control system. Thereactor vessel defines a reactor chamber including an inlet, at leastone plasma forming device for generating a plasma arc therewithin, andan outlet conduit for expelling at least one gaseous product from thereactor chamber, the at least one gaseous product having a targetcomposition of hydrocarbon-containing materials. The continuous feed-inunit is positioned for feeding the supply of solid waste feedstock tothe inlet of the reactor chamber. The output analysis system includes atleast one gas composition sensor positioned to detect at least onephysicochemical characteristic or at least one spectral characteristicof the at least one gaseous product from the reactor chamber. Thecontrol system is connected to the output analysis system and the atleast one plasma forming device and includes at least one processorprogrammed with computer executable instructions to:

control the at least one plasma forming device to apply heat at a targettemperature profile, for a target time interval, to the supply ofsolid-waste feedstock to form the at least one gaseous product havingthe target composition of hydrocarbon-containing materials;

determine an actual composition of the at least one gaseous productbased on the at least one physicochemical characteristic or at least onespectral characteristic of the at least one gaseous product; and

adjust at least one of the target time interval and the targettemperature profile of heat applied by the at least one plasma formingdevice based on a detected difference between the target composition ofthe at least one gaseous product and the actual composition of the atleast one gaseous product.

According to yet another aspect, there is provided an apparatus forplasma-based conversion of solid waste feedstock into hydrocarbongaseous products. The apparatus includes a reactor vessel, a continuousfeed-in unit, a feedstock analysis system, an output analysis system,and a control system. The reactor vessel defines a reactor chamberincluding an inlet, at least one plasma forming device for generating aplasma arc therewithin, and an outlet conduit for expelling at least onegaseous product from the reactor chamber. The continuous feed-in unit ispositioned for feeding the supply of solid waste feedstock to the inletof the reactor chamber. The feedstock analysis system is positioned tocollect and analyze a sample from the supply of solid waste feedstockfed along the continuous feed-in unit. The feedstock analysis systemincludes at least one physicochemical sensor element for detecting atleast one physicochemical characteristic of the sample of solid wastefeedstock and at least one spectral sensor element for detecting atleast one spectral characteristic of the sample of solid wastefeedstock. The output analysis system includes at least one gascomposition sensor positioned to detect at least one physicochemicalcharacteristic or at least one spectral characteristic of the at leastone gaseous product from the reactor chamber. The control system isconnected to the feedstock analysis system, the output analysis systemand the at least one plasma forming device, and includes at least oneprocessor programmed with computer executable instructions to:

characterize a composition of hydrocarbon-containing materials in thesample of solid waste feedstock based on the at least onephysicochemical characteristic and at least one spectral characteristicdetected by the feedstock analysis system;

select a target composition of the at least one gaseous product based onthe characterized composition of hydrocarbon-containing materials in thesample of solid waste feedstock;

control the at least one plasma forming device, based at least on thecomposition of hydrocarbon-containing materials in the sample of solidwaste feedstock, to apply heat at a target temperature profile, for atarget time interval, to the supply of solid-waste feedstock to form theat least one gaseous product

determine an actual composition of the at least one gaseous productbased on the at least one physicochemical characteristic or spectralcharacteristic of the at least one gaseous product; and

adjust at least one of the target time interval and the targettemperature profile of heat applied by the at least one plasma heatforming device based on a detected difference between the targetcomposition of the at least one gaseous product and the actualcomposition of the at least one gaseous product.

In some embodiments of this aspect, the target temperature profile andtarget time interval are determined by the control system based at leaston: the composition of hydrocarbon-containing materials in the sample ofsolid waste feedstock, and the target composition of the at least onegaseous product.

In some embodiments of this aspect, (which may include the above-notedembodiments), the apparatus further includes a pre-processing systemconnected for performing at least one pre-processing step on the supplyof solid waste feedstock prior to the supply of solid waste feedstockbeing fed to the inlet of the reactor chamber. Optionally, the at leastone pre-processing step performed by the pre-processing system includesa granulating process that forms a granulated supply of solid-wastefeedstock, granules of the granulated supply of solid-waste feedstockhave a size in a range from 1 mm to 10 mm.

In some embodiments of this aspect, (which may include the above-notedembodiments), the apparatus further includes a post-processing system.Optionally, the post-processing system includes least one condenser unitin fluid connection with the outlet conduit of the reactor chamber, theat least one gaseous product being passed through the at least onecondenser unit to form a liquid product from a portion of the at leastone gaseous product. As a further option, the post-processing systemincludes: a heat exchanger unit in fluid connection with the outletconduit of the reactor chamber, the at least one gaseous product beingpassed through the heat exchanger for transferring an amount of excessheat from the at least one gaseous product to a working fluid of theheat exchanger unit such that the working fluid becomes at leastpartially vaporized; and a steam turbine for generating electricity, theturbine being in fluid connection with the heat exchanger unit such thatthe partially vaporized working fluid from the heat exchanger unit isfed to the turbine to drive the motion thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments will now be described, by way of example only, withreference to the attached Figures, wherein:

FIG. 1 shows a process control diagram of a waste conversion apparatusincluding a feedstock analysis system;

FIG. 2 shows a process control diagram of a waste conversion apparatusincluding an output analysis system;

FIG. 3 shows a process control diagram of a waste conversion apparatusincluding a feedstock supply component and an output analysis system;

FIG. 4 shows a section, side-view of an embodiment of the reactor vesseland plasma torch in the waste conversion apparatus;

FIG. 5 shows a section, side-view of an alternate embodiment of thereactor vessel and plasma torch in the waste conversion apparatus;

FIG. 6 shows a cut-away, side-view of an embodiment of the reactorvessel;

FIG. 6A shows a sectional view of a magnified portion of the reactorvessel of FIG. 6 ;

FIG. 7 shows a process control diagram of a waste conversion apparatusincluding a pre-processing unit and a feedstock analysis system;

FIG. 8 shows a high-level schematic of the control system of the wasteconversion apparatus including a plurality of distributed controlsubsystems;

FIG. 9 shows a high-level schematic diagram of the control system of thewaste conversion apparatus in FIG. 1 ;

FIG. 10 shows a high-level schematic diagram of the control system ofthe waste conversion apparatus in FIG. 2 ;

FIG. 11 shows a flow-chart diagram of a first set of computer executableinstructions that are carried out on a processor of the control system;

FIG. 12 shows a flow-chart diagram of a second set of computerexecutable instructions that are carried out on a processor of thecontrol system;

FIG. 13 shows a flow-chart diagram of a third set of computer executableinstructions that are carried out on a processor of the control system;

FIG. 14 shows a flow-chart diagram of a fourth set of computerexecutable instructions that are carried out on a processor of thecontrol system;

FIG. 15 shows a flow-chart diagram of a subset of computer executableinstructions that are carried out on a processor of the control system;

FIG. 16 shows a process control diagram of a waste conversion apparatusincluding a first embodiment of a post-processing system; and

FIG. 17 shows a process control diagram of a waste conversion apparatusincluding a second embodiment of a post-processing system.

DETAILED DESCRIPTION OF THE EMBODIMENTS

For simplicity and clarity of illustration, where consideredappropriate, reference numerals may be repeated among the Figures toindicate corresponding or analogous elements. In addition, numerousspecific details are set forth in order to provide a thoroughunderstanding of the embodiment or embodiments described herein.However, it will be understood by those of ordinary skill in the artthat the embodiments described herein may be practiced without thesespecific details. In other instances, well-known methods, procedures andcomponents have not been described in detail so as not to obscure theembodiments described herein. It should be understood at the outsetthat, although exemplary embodiments are illustrated in the figures anddescribed below, the principles of the present disclosure may beimplemented using any number of techniques, whether currently known ornot. The present disclosure should in no way be limited to the exemplaryimplementations and techniques illustrated in the drawings and describedbelow.

Various terms used throughout the present description may be read andunderstood as follows, unless the context indicates otherwise: “or” asused throughout is inclusive, as though written “and/or”; singulararticles and pronouns as used throughout include their plural forms, andvice versa; similarly, gendered pronouns include their counterpartpronouns so that pronouns should not be understood as limiting anythingdescribed herein to use, implementation, performance, etc. by a singlegender; “exemplary” should be understood as “illustrative” or“exemplifying” and not necessarily as “preferred” over otherembodiments. Further definitions for terms may be set out herein; thesemay apply to prior and subsequent instances of those terms, as will beunderstood from a reading of the present description.

Modifications, additions, or omissions may be made to the systems,apparatuses, and methods described herein without departing from thescope of the disclosure. For example, the components of the systems andapparatuses may be integrated or separated. Moreover, the operations ofthe systems and apparatuses disclosed herein may be performed by more,fewer, or other components and the methods described may include more,fewer, or other steps. Additionally, steps may be performed in anysuitable order. As used in this document, “each” refers to each memberof a set or each member of a subset of a set.

The indefinite article “a” is not intended to be limited to mean “one”of an element. It is intended to mean “one or more” of an element, whereapplicable, (i.e. unless in the context it would be obvious that onlyone of the element would be suitable).

Any reference to upper, lower, top, bottom or the like are intended torefer to an orientation of a particular element during use of theclaimed subject matter and not necessarily to its orientation duringshipping or manufacture. The upper surface of an element, for example,can still be considered its upper surface even when the element is lyingon its side.

The system and processes as disclosed herein includes an apparatus forplasma-based conversion of solid waste feedstock into hydrocarbongaseous products shown at 100 (and which will, for convenience, bereferred to as the waste conversion apparatus 100), as well as a numberof processes that are implemented through the waste conversion apparatusto extract useful syngas or similar gaseous biproducts from varioustypes of waste material. The waste material provided to the wasteconversion apparatus is generally composed of various solid orsemi-solid waste products. The solid waste material that is fed into thewaste conversion apparatus is referred to herein as the supply of “wastefeedstock” or “solid waste feedstock”. The supply of waste feedstock canhave a variety of forms and compositions, but generally the compositionof the waste feedstock will include at least one carbon-containingmaterial.

Referring to FIG. 1 , an embodiment of the waste conversion apparatus100 is shown, where the waste conversion apparatus 100 is for theconversion of a supply of waste feedstock 110 into at least one gaseousproduct. The at least one gaseous product including at least onehydrocarbon-containing gaseous product. In this embodiment, the wasteconversion apparatus 100 comprises a reactor vessel 130 that defines areactor chamber 132, where the reactor chamber 132 includes an inlet134, at least one plasma forming device 140 for generating a plasma arcwithin the reactor chamber 132, and an outlet conduit 136 for expellingat least one gaseous product from the reactor chamber 132.

The waste conversion apparatus 100 also includes a continuous, feed-inunit 160 for feeding the supply of solid waste feedstock 110 to theinlet 134 of the reactor chamber 132, and a feedstock analysis system120 that is positioned to collect and analyze a sample from the supplyof solid waste feedstock 110 fed along the continuous feed-in unit 160.In the specific embodiment provided in FIG. 1 , the continuous feed-inunit 160 is a feed-in line of piping. The feedstock analysis system 120includes at least one physicochemical sensor 122 for detecting at leastone physicochemical characteristic of the sample of solid wastefeedstock, and at least one spectral sensor 124 for detecting at leastone spectral characteristic of the sample of solid waste feedstock.

Additionally, the waste conversion apparatus 100 includes a controlsystem 150 which is connected to the feedstock analysis system 120 andto the at least one plasma forming device 140 of the reactor vessel 130,and includes at least one processor 152. The at least one processor 152of the control system 150 is programmed with computer executableinstructions as presented in FIG. 11 , including instructions tocharacterize a composition of hydrocarbon-containing materials in thesample of solid waste feedstock based at least on the at least onephysicochemical characteristic and at least one spectral characteristicdetected by the sensors 122, 124 of the feedstock analysis system 120,and to control the at least one plasma forming device 140, based atleast on the composition of hydrocarbon-containing materials in thesample of solid waste feedstock, to apply heat at a target temperatureprofile, for a target time interval, to the supply of waste feedstock110 to form the at least one gaseous product.

By integrating the feedstock analysis system 120 into the wasteconversion apparatus 100, the supply of waste feedstock 110 provided tothe waste conversion apparatus 100 is characterized as the feedstock iscontinuously fed to the reactor vessel 130 within the waste conversionapparatus 100. In this way, at least one aspect of the at least oneplasma forming device 140 can be adjusted based on the physicochemicalor spectral characteristics of the sample of waste feedstock detected bythe feedstock analysis system 120.

In an additional embodiment of the waste conversion apparatus 100disclosed herein, the system includes an output analysis system 210 inplace of the feedstock analysis system 120. Referring to FIG. 2 , asecond embodiment of the waste conversion apparatus 200 is shown, wherethe waste conversion apparatus 200 is for plasma-based conversion ofsolid waste feedstock into at least one gaseous product, the at leastone gaseous product including at least one hydrocarbon-containinggaseous product. In this embodiment, the waste conversion apparatus 200comprises the reactor vessel 130 that defines the reactor chamber 132,where the reactor chamber 132 includes the inlet 134, at least oneplasma forming device 140 for generating a plasma arc within the reactorchamber 132, and the outlet conduit 136 for expelling at least onegaseous product from the reactor chamber 132. The waste conversionapparatus also includes the continuous, feed-in unit 160 for feeding thesupply of solid waste feedstock 110 to the inlet 134 of the reactorchamber 132, and an output analysis system 210 including at least onegas composition sensor 212 for detecting at least one physicochemicalcharacteristic or spectral characteristic of the at least one gaseousproduct from the reactor chamber 132.

Lastly, the apparatus includes the control system 150 which is connectedto the output analysis system 210 and to the at least one plasma formingdevice 140 of the reactor vessel 130, and includes at least oneprocessor 152. The at least one processor 152 of the control system 150is programmed with computer executable instructions as presented in FIG.13 , including instructions to control the at least one plasma formingdevice 140 to apply heat at a target temperature profile, for a targettime interval, to the supply of waste feedstock 110 to form the at leastone gaseous product having a target composition ofhydrocarbon-containing materials, and determine an actual composition ofthe at least one gaseous product based on the at least onephysicochemical characteristic or spectral characteristic of the atleast one gaseous product. The at least one processor 152 of the controlsystem 150 is further programmed with computer executable instructionsto adjust at least one of the target time interval and the targettemperature profile of heat applied by the at least one plasma heatforming device 140 based on a detected difference between the targetcomposition of the at least one gaseous product and the actualcomposition of the at least one gaseous product.

In a further embodiment of the waste conversion apparatus 100 asdisclosed herein, the waste conversion apparatus 100 is structured toinclude the feedstock analysis system 120 and the output analysis system210, both of which are communicatively connected to the at least oneprocessor 152 of the control system 150 and provide a combinedfunctionality of the embodiments presented in both FIGS. 1 and 2 .Processes executed on this embodiment of the waste conversion apparatusare described in greater detail below with specific reference to FIG. 14.

In an embodiment, the supply of waste feedstock 110 that is provided tothe waste conversion apparatus 100 has a composition that includes atleast one of a municipal solid waste material, a hazardous wastematerial, coal of varying grades, pulp and paper waste material, woodproducts such as shredded bark, wood chips or sawdust, sewage and sewagesludge material, food waste material, plant matter, rice straw material,agricultural and animal waste material, and cellulosic type industrialwaste (e.g., construction wastes).

In an embodiment, the supply of waste feedstock 110 provided to theinlet of the reactor chamber 132 is composed of both organic andinorganic, solid waste material.

In an embodiment, the at least one gaseous product includes at least onesyngas product such as gaseous ammonia, gaseous hydrogen, or othergaseous hydrocarbons.

Referring to FIG. 3 , the waste conversion apparatus 100 includes acontinuous feed-in unit 160 for feeding the supply of solid wastefeedstock 110 to the inlet 134 of the reactor chamber 132. In anembodiment such as the embodiment provided in FIG. 3 , the continuousfeed in unit 160 includes a feedstock supply conduit 322 that provides acontinuous supply of the waste feedstock to the waste conversionapparatus 100. In an embodiment, the continuous feed-in unit 160 of theapparatus 100 includes a feedstock supply component 330 that provides acontinuous or near-continuous supply of waste feedstock 110 to the wasteconversion apparatus 100.

In the specific embodiment provided in FIG. 3 , the feedstock supplycomponent 330 includes a feedstock supply pump 320 for providing thesupply of waste feedstock 110 to the reactor chamber 132 of the reactorvessel 130. The feedstock supply component 330 also includes thefeedstock supply conduit 322 in the form of a pipe or a non-coveredtransport conduit such as a conveyor belt or conveyor mechanism. Thefeedstock supply conduit 322 transports the supply of waste feedstock110 to the inlet of the reactor vessel 130.

In an embodiment, the waste feedstock that is to be continuouslysupplied to the waste conversion apparatus 100 is contained in thefeedstock supply component 330 prior to its introduction to the wasteconversion apparatus 100. In a specific embodiment provided in FIG. 3 ,the feedstock supply component 310 also includes at least one feedstocksupply reservoir 310 that holds a volume of the waste feedstock. Thefeedstock supply component includes the supply pump 320 and the at leastone feedstock supply reservoir 310 connected to the inlet 134 of thereactor chamber 132 via the feedstock supply conduit 322.

In an embodiment, the inlet of the reactor vessel 130 is in parallelconnection with both the feedstock analysis system 120 and the feedstocksupply component 330. In this way, the sample volume of the supply ofwaste feedstock 110 that is extracted to the feedstock analysis system120 will be added back to the supply of waste feedstock 110 provided tothe reactor chamber 132 of the reactor vessel 130 via the inlet 134.

In an additional embodiment, the feedstock supply conduit 322 is in theform of a plurality of pipes, and the at least one feedstock supplyreservoir 310 is a plurality of supply reservoirs. Each of the pluralityof supply reservoirs includes at least a portion of the supply of wastefeedstock 110 and the plurality of pipes provide the portions of thesupply of waste feedstock 110 to the inlet 134 of the reactor vessel130.

In an embodiment, the feedstock supply conduit 322 is a plurality ofconduits coming from each of the plurality of supply reservoirs thatmerge to combine each the feedstock from each supply reservoir toproduce a combined supply of waste feedstock.

Reactor Vessel

As disclosed previously, the waste conversion apparatus 100 includes atleast one plasma forming device 140, the at least one plasma formingdevice 140 generating a plasma arc within the reactor chamber 132 thatis applied to the supply of solid waste feedstock 110 within the reactorchamber 132.

In the specific embodiment provided in FIG. 4 , the at least one plasmaforming device 140 is a plasma torch 420 such as a direct-current plasmatorch. In this embodiment, the plasma torch 420 is connected to anexternal power supply unit 424 that provides a driving voltage to thedirect-current plasma torch. The plasma torch 420 is also connected toan external gas supply unit 426 that provides a supply of at least oneplasma-forming gas to the plasma torch 420. In this embodiment, adirect-current, plasma arc 428 formed by the plasma torch 420 willextends beyond a plasma forming tip of the direct-current plasma torch.

Referring to FIGS. 4 and 5 , an embodiment of the reactor vessel 130,400 that defines a reactor chamber 132 is provided. As disclosedpreviously, the reactor vessel 130, 400 includes the inlet 134 forproviding a supply of solid waste feedstock 110 thereto, the at leastone plasma forming device 140 for generating a plasma arc within thereactor chamber 132, and the outlet conduit 136 for expelling at leastone gaseous product. In the specific embodiment provided in FIG. 4 , thefeedstock supply conduit 322 is a supply pipe 470 in fluid connectionwith the inlet 134 of the reactor vessel 130. In this embodiment, theinlet 134 is an inlet pipe 434, where the supply pipe 470 is sized tocorrespond to the size of the inlet pipe 434. The outlet conduit 136 isan outlet aperture 436 in fluid connection with the reactor chamber 132.

In an embodiment, the wall 410 of the reactor vessel 130 includes atleast one thermal insulation layer that is integrally formed as part ofthe wall 410, were the at least one thermal insulation layer allows formore accurate maintaining of the process temperature.

In an embodiment, the wall 410 of the reactor vessel 130 has a thicknessof at least 4 mm.

In an embodiment, the reactor vessel 130 is composed of a metal materialsuch as stainless steel.

In the specific embodiment provided in FIG. 6 , the wall 410 of thereactor vessel 130 is a multi-layer wall 600. A portion of the wall 600is shown in a dotted rectangle at 601. The portion is magnified in FIG.6A. In the example shown in FIG. 6A, the wall 600 includes an innermostlayer 610 that may be a heat-resistant cement layer, a firstintermediate layer 620 that may be a polycrystalline-mullite fiberlayer, a second intermediate layer 630 that may be a fiber glass layer,and an outermost layer 640 that may be a stainless steel layer. Thethicknesses of these layers 610, 620, 630 and 640, may be: about 3 cmfor the innermost layer 610, about 10 cm for the first intermediatelayer 620, about 2 cm for the second intermediate layer 630 and about 4mm for the outermost layer 640. The outermost layer 640 may also bereferred to as a support layer since in at least some embodiments, itsupports the intermediate and inner layers 620, 630 and 610.

In other embodiments, the multi-layer wall 600 may include any suitablerefractory material as the innermost layer 610, and any suitableoutermost or support layer 640, such as a layer of stainless steel, andmay or may not include any intermediate layers.

In the specific embodiment provided in FIGS. 4 and 5 , the reactorvessel 130, 400 is approximately cylindrical in form and includes acorrespondingly shaped reactor chamber 132. In this embodiment, the atleast one plasma forming device 140 is the plasma torch 420, and theplasma torch 420 is mounted along a torch mounting channel 422 in thewall 410 of the reactor vessel 130, 400. In the embodiment of FIG. 5 ,the torch mounting channel 422 is formed within the wall 410 of thereactor vessel 130, 400 such that a plasma forming end of the plasmatorch 420 is positioned at a predetermined distance (D1) from a bottomsurface 532 of the reactor chamber 132. In an additional embodiment, thetorch mounting channel 422 is formed in the wall 410 of the housing suchthat when the plasma torch 420 is mounted in the torch mounting channel422, the plasma torch 420 is inclined at an angle (Ω) relative to a longaxis (L) of the reactor vessel 130. When the plasma torch 420 is mountedand inclined at an angle (Ω), the plasma torch 420 will generate acentrifugal flow within the reactor chamber 132 due to the orientationof a jet of plasma gas from the plasma torch 420 within the reactorchamber 132. This centrifugal flow can rotate about an essentiallyhorizontal axis of the reactor chamber 132, above the bottom surface 532of the reactor chamber 132. In this embodiment, the flow of plasma gaswithin the reactor chamber 132 melts fly ash and unburned wastefeedstock from the supply of solid waste feedstock 110 onto the wall 410of the reactor chamber 132. By melting the fly ash and unburned wastefeedstock, the emission of fly ash through the outlet conduit of thereactor vessel 130 will be reduced, thereby reducing the amount ofcontaminants within the at least one gaseous product.

In the specific embodiment of the reactor vessel 130 provided in FIG. 5, the torch mounting channel has an inner diameter of 15 cm, however,other diameters may be suitable, and the angle (Ω) of the torch mountingchannel relative to the long axis (L) of the reactor vessel 130 is in atan angle of about 45 degrees from a vertical axis, however other anglesmay be suitable. In this instance, ‘about 45 degrees’ may vary from 45degrees by up to 5 degrees up or down, depending on the particularapplication, and may vary by more, depending on the application.

In an additional embodiment, the torch mounting channel 422 is formed inthe wall 410 of the reactor vessel 130 such that when the plasma torch420 is mounted in the torch mounting channel 422, the plasma forming endof the plasma torch 420 extends within a bottom half of the reactorchamber 132.

In an embodiment such as the embodiment provided in FIG. 5 , the reactorvessel 130 further includes at least one gas inlet tube 536 in fluidcommunication with the reactor chamber 132 of the reactor vessel 130.The at least one gas inlet tube 536 extends through the wall 410 of thereactor vessel 130 and is provided as a means for adding gaseous processadditives to the reactor chamber 132. The gaseous process additives canmodify or improve an efficiency of processes performed within thereactor vessel 130 of the waste conversion apparatus 100. The at leastone gas inlet tube 536 can include a control valve for allowing orpreventing flow along the gas inlet tube 536.

In an additional embodiment, the at least one gas inlet tube 536 isformed in the wall 410 of the reactor vessel 130, as part of the reactorvessel 130 such that the at least one gas inlet tube 536 is inclined atan angle relative to the long axis (L) of the reactor vessel 130.

In an additional embodiment, the reactor vessel 130, inlet 134, andoutlet conduit 136 are each composed of a metal material such asstainless steel, however, any other suitable material may be used.

In the embodiments where the slag drain pipe 534 is spaced above thebottom surface 532 of the reactor chamber 132, the reactor chamber 132is formed to hold a volume of molten metal and glass therewithin, thevolume of molten metal and glass acting as a thermal mass in order toreduce an amount of thermal energy that needs to be added by the atleast one plasma forming device 140 to break down the supply of wastefeedstock 110.

In an embodiment, the reactor chamber 132 includes at least one infraredheating element disposed therein. The at least one infrared heatingelement is for further controlling a temperature within the reactorchamber 132 to reduce the time and electrical power required to preheatthe reactor chamber 132 of the reactor vessel 130 prior to the use ofthe at least one plasma forming device 140.

In an embodiment, the reactor vessel 130 includes an evacuation conduitthat fluidly connects the reactor chamber 132 to an evacuation pump. Theevacuation pump can evacuate gases out of the reactor chamber 132 priorto the gasification and pyrolysis process to achieve a predeterminedreactor pressure. In an exemplary embodiment, the reactor pressure isapproximately atmospheric pressure and the evacuation pump is a vacuumpump.

In the embodiment provided in FIGS. 4 and 5 , the reactor vessel 130,400 includes a plurality of reactor support legs 450 that form a reactorbase. The reactor support legs 450 of the reactor vessel 130, 400 arefixed to a mounting surface. In an alternate embodiment, the reactorsupport legs 450 are formed such that the reactor vessel 130, 400 ismovable.

In an additional embodiment as shown in 7, the reactor vessel 130includes a slag drainage conduit 720 that is in fluid connection withthe reactor chamber 132 of the reactor vessel 130. The slag drainageconduit 720 is positioned to drain out waste, inert slag that is formedduring the pyrolysis and gasification of the supply of waste feedstock110 within the reactor chamber 132.

In an additional embodiment, the slag drainage conduit 720 is in fluidconnection with a waste storage unit that is sized to hold the waste,inert slag produced in the reactor chamber 132.

In the specific embodiment provided in FIG. 5 , the slag drainageconduit 720 is a slag drain pipe 534 formed in a bottom half of thereactor vessel 130. The slag drain pipe 534 is formed in the bottom halfof the reactor vessel 130 such that an inlet of the slag drain pipe 534is positioned at a height (D2) above the bottom surface 532 of thereactor chamber.

In an additional embodiment, the height (D2) of the inlet of the slagdrain pipe 534 is between 0.5 and 2 cm.

In an additional embodiment, the reactor vessel 130 includes an aperture440 in the wall 410 thereof that extends to the reactor chamber 132. Theaperture 440 functions as a window for monitoring the reaction processoccurring within the reactor chamber 132. In an specific embodimentprovided in FIGS. 4 and 5 , the aperture 440 is a viewing windowpositioned on the wall 410 of the reactor vessel 130 such that aplasma-forming end of the at least one plasma forming device 140 isvisible through the aperture 440. In an additional embodiment, theaperture 440 is filled with a transparent material such asheat-resistant glass.

In an embodiment, at least one of the reactor vessel 130 and the atleast one plasma forming device 140 include an integrated cooling systemfor regulating a temperature of the reactor vessel 130 and the at leastone plasma forming device 140. In a specific embodiment, the integratedcooling system is connected to an external coolant supply system thatcirculates a coolant fluid through the integrated cooling systems of thewaste conversion apparatus 100.

Referring to FIG. 7 , the waste conversion apparatus 100 as disclosedherein further comprises a pre-processing system positioned upstream ofthe continuous feed-in unit 160, where the pre-processing systemincludes at least one pre-processing unit 710 that is for drying andsorting the supply of waste feedstock 110. The drying and sorting of thesupply of waste feedstock 110 is through any of a manual means, anautomated means, or a combined manual and automated means within the atleast one pre-processing unit 710 of the pre-processing system.

In a specific embodiment of the waste conversion apparatus 100 where thefeedstock supply component 330 includes at least one feedstock supplyreservoir 310, the feedstock supply reservoir 310 is configured as theat least one pre-processing unit 710.

In an alternate embodiment such as the embodiment provided in FIG. 7 ,the at least one feedstock supply reservoir 310 is separate from butconnected to the at least one pre-processing unit 710.

In a specific embodiment, the pre-processing unit 710 includes ashredding component, where the supply of waste feedstock 110 is shreddedby the shredding component such that there are no particles of wasteproduct in the supply of waste feedstock 110 are above a pre-determinedsize. The shredding component can include one or multiple shreddingsteps carried out by one or more shredding mechanisms.

In a first exemplary embodiment, the supply of waste feedstock 110 isshredded such that the particles of the supply of waste feedstock 110are no more than 10 mm in diameter. In an additional exemplaryembodiment, the solid waste feedstock is pre-processed by thepre-processing system such that the supply of waste feedstock 110 isgranulated to produce granules of the solid-waste feedstock having asize in a range from 1 mm to 10 mm.

In an additional embodiment, the pre-processing unit 710 includes adrying component where the supply of waste feedstock 110 is dried suchthat a moisture content of the supply of waste feedstock 110 is lessthan 7 wt. %.

Feedstock Analysis System

As disclosed previously, an embodiment of the waste conversion apparatus100 includes a feedstock analysis system 120. The feedstock analysissystem 120 is positioned to collect and analyze a sample from the supplyof solid waste feedstock 110 that is fed along the continuous feed-inunit 160. The feedstock analysis system 120 includes at least onephysicochemical sensor 122 for detecting at least one physicochemicalcharacteristic of the sample of solid waste feedstock, and at least onespectral sensor 124 for detecting at least one spectral characteristicof the sample of solid waste feedstock.

In an embodiment, the feedstock analysis system 120 includes a feedstocksampling unit that is formed to extract a sample volume of the supply ofsolid waste feedstock 110 that is being fed along the continuous feed-inunit 160. In a specific embodiment such as the embodiment provided inFIG. 1 , the feedstock sampling system includes a feedstock samplingconduit 128 that is in fluid connection with the continuous feed-in unit160. The feedstock sampling conduit 128 is connected to the continuousfeed-in unit 160 and is provided with a means for extracting the samplevolume of the supply of solid waste feedstock 110. In an exemplaryembodiment of the means for extracting the sample, the feedstocksampling system includes a pump in fluid connection with the feedstocksampling conduit 128, where the pump generates a pressure differencealong the feedstock sampling conduit 128 to extract the sample volume ofthe supply of solid waste feedstock 110.

In an embodiment, the feedstock sampling conduit 128 is connected to asampling reservoir within which the sample volume of the supply of solidwaste feedstock 110 is analysed by the feedstock analysis system 120.

In an embodiment where the feedstock is provided as a continuous ornear-continuous supply of waste feedstock 110, the feedstock analysissystem 120 of the waste conversion apparatus 100 is used to continuouslyor near-continuously collect and analyze a sample of the supply of wastefeedstock 110.

Referring to FIG. 9 , the feedstock analysis system 120 of the wasteconversion apparatus 100 includes the at least one physicochemicalsensor 122 and the at least one spectral sensor 124, where these sensorsare directly connected to at least one processor 152 of the controlsystem 150. The at least one physicochemical characteristic and the atleast one spectral characteristic detected by the sensors 122, 124 ofthe feedstock analysis system 120 are communicated directly to the atleast one processor 152 of the control system 150 of the wasteconversion apparatus 100. In this embodiment, the feedstock analysissystem 120 functions to acquire data related at least onephysicochemical and at least one spectral characteristic of the supplyof solid waste feedstock 110.

In the specific embodiment provided in FIG. 9 , the at least onephysicochemical sensor 122 of the feedstock analysis system 120 includesat least one physical sensor 922 a that will detect the at least onephysical characteristic and at least one chemical sensor 922 b that willdetect at least one chemical characteristic of the supply of solid wastefeedstock 110.

In an embodiment, the at least one physicochemical sensor 122 is aplurality of sensors capable of detecting at least one physicochemicalcharacteristic of the supply of waste feedstock 110. The at least onephysicochemical sensor 122 may include any or more of a temperatureprobe, a thermocouple, a calorimeter, a thermogravimetric analyzer, anda differential scanning calorimetry (DSC) probe. In this embodiment, theat least one physicochemical characteristic is any one or more of aweight, a thermal stability, a heat duty, and a reactant potentialenergy of the supply of solid waste feedstock 110.

In an exemplary embodiment, the at least one spectral sensor 124 is anyone or more of a mass spectrometer, an IR detector, a Fourier transforminfrared (FTIR) spectrometer, a scanning electron microscope, a coupledx-ray emitter and detector, and a Raman spectrometer. The at least onespectral characteristic is any one or more of a spectral reflectance,spectral transmittance, and spectral absorptance of the supply of solidwaste feedstock 110 for any of an ultraviolet, visible, and infraredfrequencies.

In an alternate embodiment, the feedstock analysis system 120 isconnected within the waste conversion apparatus 100 to perform one ormore analysis steps on the data of the sample of waste feedstockacquired by the at least one physicochemical sensor 122 and the at leastone spectral sensor 124 of the feedstock analysis system 120. Referringto FIG. 9 , the feedstock analysis system 120 includes at least onefeedstock analysis processor that is connected to the at least onephysicochemical sensor and the at least one spectral sensor, and to theat least on processor of the control system 150. These one or moreanalysis steps are performed separate from of the at least one processor152 of the control system 150. In the specific embodiment provided inFIG. 9 , the at least one feedstock analysis processor is two feedstockanalysis processors 926 a, 926 b, one connected to the at least onepsychochemical sensor 122 and one connected to the at least one spectralsensor 124. The two feedstock analysis 926 a, 926 b processors analyzethe at least one physical characteristic and at least one chemicalcharacteristic of the sample of solid waste feedstock detected by the atleast one physicochemical sensor 122 and the at least spectralcharacteristic detected by the spectral sensor 124 to characterize acomposition of hydrocarbon containing material in the supply of solidwaste feedstock 110.

Output Analysis System

As disclosed previously, an embodiment of the waste conversion apparatus200 (shown in FIG. 2 ) includes an output analysis system 210 thatincludes at least one gas composition sensor 212, where the gascomposition sensor 212 is positioned to detect at least onephysicochemical characteristic or spectral characteristic of the atleast one gaseous product from the reactor chamber 132. The outputanalysis system 210 is communicatively connected to the at least oneprocessor 152 of the control system 150 in the waste conversionapparatus 100.

In an embodiment shown in FIG. 10 , the at least one gas compositionsensor 212 of the output analysis system 210 is directly connected to atleast one processor 152 of the control system 150. The at least onephysicochemical characteristic or the at least one spectralcharacteristic of the at least one gaseous product detected by theoutput analysis 210 system are communicated directly to the at least oneprocessor 152 of the control system 150 of the waste conversionapparatus 100.

In the specific embodiment provided in FIG. 10 , the at least one gascomposition sensor 212 of the output analysis system 210 includes aphysicochemical sensor 1012 a that will detect the at least onephysicochemical characteristic and a spectral sensor 1012 b that willdetect at least one spectral characteristic of the at least one gaseousproduct.

In an embodiment, the at least one gas composition sensor 212 includesany of a temperature sensor, a pressure sensor, a thermocouple, acalorimeter, or a differential scanning calorimetry (DSC) probe. In thisembodiment, the at least one physicochemical or spectral characteristicof the at least one gaseous product is any of a weight, a temperature,an pressure, a thermal stability, a heat duty, a spectral reflectance,spectral transmittance, and spectral absorptance of the at least onegaseous product.

In an embodiment, the output analysis system 210 also includes an outputsampler that is formed to extract a sample volume of the at least onegaseous product that is expelled along the outlet conduit or the reactorchamber 132. In this embodiment, the output sampler includes a gassampling conduit that is in fluid connection with outlet conduit 136 ofthe reactor chamber 132, where the output sampler extracts the samplevolume of the at least one gaseous product to a gas sampling reservoirwhich contains the at least one gas composition sensor 212 positioned todetect at least one physicochemical characteristic or spectralcharacteristic of the at least one gaseous product.

In an alternate embodiment, the at least one gas composition sensor 212detecting the at least one physicochemical characteristic or spectralcharacteristic of the at least one gaseous product is directly providedwithin the outlet conduit 136 of the reactor chamber 132.

In the specific embodiment provided in FIG. 10 , the output analysissystem 210 is connected within the waste conversion apparatus 100 toperform one or more analysis steps based on the at least onephysicochemical characteristic and the at least one spectralcharacteristic detected by the at least one gas composition sensor. Inthis embodiment, the output analysis system 210 includes at least oneoutput analysis processor 1014 that is connected to the at least one gascomposition sensor 212 and the at least one processor 152 of the controlsystem 150. The output analysis processor 1014 includes computerexecutable instructions that, when executed will cause the outputanalysis processor 1014 to analyze the at least one physicochemicalcharacteristic and the at least one spectral characteristic detected bythe at least one gas composition sensor 212 to determine a compositionof the at least one gaseous product.

Control System

As disclosed above, the waste conversion apparatus 100 includes thecontrol system 150 that, in its various embodiments (See FIGS. 7, 9 and10 ), is connected to the at least one plasma forming device 140 and toone or both of the feedstock analysis system 120 and the output analysissystem 210. In these various embodiments, the control system 150controls the at least one plasma forming device 140 to achieve atemperature profile for the conversion of the supply of waste feedstock110 into the at least one gaseous product. The control system 150provides for the production of the at least one gaseous product having aspecified composition.

As shown in FIGS. 7, 9 and 10 , the control system 150 includes at leastone processor 152 programmed with computer executable instructions forcontrolling the waste conversion apparatus 100 to execute severalreaction processes.

The control system 150 of the waste conversion apparatus 100 isstructured as various types of control system architecture suitable forthe system 150 as disclosed herein. The control system 150 is structuredas any one of a substantially centralized control system including acentral, networked processor, a distributed control system including aseries of distributed processors, or a combination centralized anddistributed control system.

In the specific embodiment provided in FIG. 8 , the control system 150,800 is subdivided into separate yet communicatively linked local controlsubsystems 810, each of the linked control subsystems 810 including atleast one processor associated therewith. Such an architecture enables agiven process or set of processes to take place and be controlledlocally with minimal interaction with other subsystems 810. In thisembodiment, the control system 150, 800 also includes a master controlsystem 820 including at least one processor 152, 852 that communicateswith each respective local control subsystem 810 for controlling anoverall process within the waste conversion apparatus 100. The localcontrol subsystems 810 are linked to the master control system 820 via awired or wireless connection.

In the specific embodiment provided in FIG. 8 , a wireless network 830is provided to connect the control subsystems 810 to the master controlsystem 820. The control system is also in communication with a large,public network, such as the Internet 840. FIG. 8 shows various physicalelements of the master control system 820, including the processor 152,852 processing unit, an input/output (“I/O”) interface 826 and a storagecomponent 824. The storage component 824 includes both random accessmemory (“RAM”) and non-volatile storage. Non-volatile storage in thestorage component 824 stores the operating system and programs,including at least some of the computer-executable instructions asdescribed herein. The RAM of the storage component 824 providesrelatively-responsive volatile storage to the at least one processor152, 852 of the master control system 820. The I/O interface 826 allowsfor input to be received from one or more devices, such as a keyboard, amouse, etc., and outputs information to output devices, such as adisplay and/or speakers.

In an embodiment as shown in FIGS. 9 and 10 , the control system 150 isconnected to the at least one plasma forming device 140, to at least oneof the feedstock analysis system 120 and the output analysis system 210,and includes at least one other control subsystem 900 that is integratedwithin the waste conversion apparatus 100 as disclosed herein. In thisembodiment of the waste conversion apparatus 100, the at least one othercontrol subsystem 900 includes at least one sensor element 910associated with at least one component of the waste conversion apparatus100, for detecting at least one operating characteristic associated withthe at least one of the component of the waste conversion apparatus 100.The at least one other control subsystem 900 also includes at least onecontrol element 930 associated with at least one component of the wasteconversion apparatus 100 for adjusting at least one operating parameterof at least one component of the waste conversion apparatus 100.

In an embodiment, the at least one control element 930 includes anactuator element that is controlled to be actuated by the at least oneprocessor 152 of the control system 150.

In an embodiment, the at least one processor 152 of the control system150 is programmed with computer executable instructions to compare theat least one operating characteristic detected by the at least onesensor element 910 of the at least one control subsystem 900 to suitableranges of such characteristics, and to produce a response in the atleast one control element 930 of the control subsystem 900.

The at least one sensor element 910 and the at least one control element930 is associated with the same component of the waste conversionapparatus 100 or wholly different components of the waste conversionapparatus 100. The at least one sensor element 910 and the at least onecontrol element 930 may thus be distributed throughout at least onecomponent of the waste conversion apparatus 100 or in relation to atleast one component thereof, to detect characteristics associated withprocesses occurring in the various components of the waste conversionapparatus 100.

In an embodiment, the at least one processor 152 of the control system150 controls the at least one control element 930 based on the at leastone operating characteristic monitored by the at least one sensorelement 910.

In an additional embodiment, the control system 150 produces a responsewithin at least one of the control elements 930 due to the at least onesensor elements 910 detecting an operating characteristic exceeding orfalling below a threshold value, or falling outside of a predeterminedrange. In an alternate embodiment, the control system 150 produces aresponse within the at least one of the control element 930 of thecontrol subsystem 900 due to a detected differential signal betweenseveral of the at least one sensor element 910.

In an embodiment, the control system 150 controls the at least onecontrol element 930 based on the at least one physicochemicalcharacteristic or the at least one spectral characteristic detected bythe at least one physicochemical sensor 122 and the at least onespectral sensor 124 of the feedstock analysis system 120.

In an embodiment, the control system 150 controls the at least onecontrol element 930 of the control subsystem 900 based on the at leastone physicochemical characteristic or the at least one spectralcharacteristic detected by the at least one gas composition sensor 212of the output analysis system 210.

As will be readily understood from the above disclosures, the at leastone control element 930 and at least one sensor element of the controlsystem 150 are implemented into various components of the wasteconversion apparatus 100.

In the specific embodiments provided in FIGS. 9 and 10 , the at leastone physicochemical sensor 122 and the at least one spectral sensors 124of the feedstock analysis system 120 are connected to the at least oneprocessor 152 in addition to the at least one sensor element 910.Likewise, the at least one gas composition sensor 212 of the outputanalysis system 210 is connected to the at least one processor 152 inaddition to the at least one sensor element 910.

In an alternate embodiment of the waste conversion apparatus 100, one ormore of the at least one physicochemical sensor 122, the at least onespectral sensor 124 and the gas composition sensor 212 are connected tothe at least one processor 152 of control system 150 and function as thesensor element 910 of the control subsystem 900.

In a specific embodiment that will understood based off the abovedescription of the at least one plasma forming device 140 and theconnection to the control system 150 thereof, an embodiment of thecontrol system 150 is structured where the at least one control element930 is a component of the at least one plasma forming device 140. Inthis way, the at least one control element 930 is controlled by thecontrol system 152 to regulate the at least one plasma forming device140, thereby controlling the temperature profile or the time interval ofheat applied by the at least one plasma forming device 140.

In the specific embodiment where the at least one plasma forming device140 is at least one plasma torch 420, the component of the plasma torch420 that is the at least one control element 930 is any of the gassupply 426 of the at least one plasma torch or the external power supply424 of the plasma torch.

In an additional embodiment, the at least one control element 930 of thecontrol subsystem 900 is actuator that drives a rate of feed-in of thesupply of waste feedstock 110 by the continuous feed-in system 160. Inthis way, a rate of the supply of waste feedstock 110 that is providedto the reactor chamber 132 of the reactor vessel 130 is varied by thecontrol system 150.

In an embodiment, the at least one control element 930 of the controlsubsystem 900 is a flow regulating element provided at the gas inlettube 536 of the reactor chamber 132. In this way, an amount, a type or arate of process additives that are injected into the reactor chamber 132is controlled by the control system 150.

In an embodiment, the at least one sensor element 910 of the controlsubsystem 900 is at least one flow measurement sensor. In an additionalembodiment, some or all of the openings, conduits and inlets of thereactor vessel 130 (such as the reactor inlet 134, outlet conduit 136,gas inlet tube 536 or slag drainpipe 720) each include a sensor element910 that is a flow measurement sensor. In this embodiment, the at leastone control element 930 is a plurality of actuators associated with someor all of the openings, conduits and inlets that include an associatedsensing element 910. The actuator is any suitable physical componentsfor regulating fluid flow such as a flow regulating valve or a pressurerelease valves. In this embodiment, the control system 150 controls aresponse of some or all of the control elements 930 based on a detectedcharacteristic from the at least one sensing element 910.

In an embodiment, the at least one control element 930 of the controlsubsystem 900 includes the at least one infrared heating element withinthe reactor chamber 132.

In an embodiment, the at least one sensor 910 of the control system 150is at least one reactor sensor detecting a reading associated with afirst characteristic within the reactor chamber 132 of the reactorvessel 130. The at least one reactor sensor is connected to the at leastone processor 152 of the control system 150 and is generally disposedwithin the reactor vessel 130.

In an embodiment, the reactor vessel 130 is controlled by the controlsystem 150 to prepare a high-temperature and oxygen-deprived environmentwithin the reactor chamber 132 such that the hydrocarbon-containingconstituents of the supply of solid waste feedstock 110 are transformedinto the at least one syngas product with a conversion rate of at least99%.

In an embodiment, the reactor vessel 130 and at least one plasma formingdevice 140 are designed such that an internal reactor chambertemperature of between 1300 to 1500 degrees Celsius is realized. In thisembodiment, the temperature achieved within the reactor chamber 132 isgreat than the standard melting point of feedstock ash and tar, therebyproviding a more complete destruction of any residual tar and ash thatis produces during the plasma gasification and pyrolysis of the supplyof solid waste feedstock 110.

In an embodiment such as the embodiment provided in FIG. 5 , the atleast one reactor sensor is at least partially exposed to the reactorchamber 132 of the reactor vessel 130. In this embodiment, the at leastone reactor sensor is any of a temperature sensor, a flow sensor, apressure sensor or other suitable or known sensor elements formonitoring a characteristic of a reaction process. In the specificembodiments provided in FIGS. 4 and 5 , the at least on reactor sensorincludes a pressure sensor 454 in the form of a pressure transduce formonitoring the pressure inside the reactor chamber 132, and atemperature sensor 452 in the form of a thermocouple tube for monitoringthe temperature inside the reactor chamber 132 during the gasificationand pyrolysis process of the supply of waste feedstock 110.

In a first embodiment provided in FIG. 11 , the control system 150 asdescribed herein controls at least one process that is implemented bythe various systems and subsystems of the waste conversion apparatus100. Referring to FIG. 11 , the at least one processor 152 of thecontrol system 150 connected to the feedback analysis system isprogrammed with computer executable instructions including a first step(1110) of characterizing a composition of hydrocarbon-containingmaterials in the sample of solid waste feedstock based at least on theat least one physicochemical characteristic and at least one spectralcharacteristic detected by the feedstock analysis system 120, and asecond step (1120) of controlling the at least one plasma forming device140, based at least on the composition of hydrocarbon-containingmaterials in the sample of solid waste feedstock, to apply heat at atarget temperature profile, for a target time interval, to the supply ofwaste feedstock 110 to form the at least one gaseous product.

Characterizing Composition of Feedstock

The first step (1110) of characterizing a composition ofhydrocarbon-containing materials in at least one sample of solid wastefeedstock is completed by the at least one processor 152 of the controlsystem 150 based at least partially on the at least one physicochemicaland spectral properties detected by the feedstock analysis system 120.

In an embodiment where the at least one physicochemical sensor 122 andthe at least one spectral sensor 124 are connected to the at least oneprocessor 152, feedstock data detected by the at least one spectralsensor 124 and at least one physicochemical sensor 122 is provided tothe at least one processor 152 for analysis and for characterizing acomposition of the sample of waste feedstock.

Referring to FIG. 15 , in analyzing the feedstock data to determine thecomposition of the sample of waste feedstock, the at least one processor152 is programmed with computer executable instructions to perform atleast one physicochemical analysis step (1510) and at least one spectralanalysis step (1520) based on the respective on the at least onephysicochemical characteristic and the at least one spectralcharacteristic of the feedstock. In performing the at least onephysicochemical analysis step (1510) and the at least one spectralanalysis step (1520), the at least one processor 152 can perform atleast one computational step on a feedstock data associated with eachanalysis step.

In this embodiment, the physicochemical analysis step (1510) is varioussuitable physicochemical analysis procedures including athermogravimetric analysis, an analysis to determine a fraction ofvolatile material, or a DSC analysis (heat flow analysis).

In this embodiment, the spectral analysis step (1520) is varioussuitable spectroscopic analysis procedures including an FTIR analysis,an SEM analysis, a coupled x-ray emitter and detector, or an ETCanalysis

In an embodiment, the at least one of the physicochemical analysis step(1510) and the spectral analysis step (1510) each include a step ofretrieving at least one physicochemical characteristic or at least onespectral characteristic of a known compound from a existing dataset ofknown chemical compounds (1510 a, 1520 a). In an third step (1530), theat least one physicochemical characteristic and at least one spectralcharacteristic of the known compound are compared to the at least onephysicochemical characteristic and at least one spectral characteristicof the supply of solid waste feedstock 110. In comparing thephysicochemical and spectral characteristics, physical, chemical andspectral properties of the sample of waste feedstock are determined

In a specific embodiment, the existing dataset of known chemicalcompounds is stored in a database system contained in a memory of the atleast one processor 152. In an alternate embodiment, the database systemis stored on an external computerized medium and the at least oneprocessor 152 of the control system 150 includes suitable hardware orsoftware connections to retrieve at least one physicochemicalcharacteristic and at least one spectral characteristic of a knowncompound from this external database.

In a fourth step (1540), the at least one processor 152 of the controlsystem 150 will generate a reaction mechanism model based on thephysical, chemical and spectral properties of the sample of wastefeedstock

In a final step (1550) the composition of materials in the supply ofsolid waste feedstock 110 is characterized. In a first embodiment, thecontrol system 150 characterizes the composition of materials in thesupply of waste feedstock 110 based on the sample of physicochemicalanalysis step, the spectral analysis step, and at least one additionalanalysis step based on a result of the physicochemical analysis step andthe spectral analysis step. In an alternate embodiment, the feedstockanalysis system 120 and control system 150 characterizes the compositionof materials in the supply of waste feedstock 110 based on the reactionmechanism model generated by the at least one processor 152 of thecontrol system 150.

As disclosed in previous embodiments, the supply of solid wastefeedstock 110 can be provided at a continuous or a near continuous rateto the waste conversion apparatus 100. In an embodiment of the wasteconversion apparatus 100, a continuous or a near continuous supply ofsolid waste feedstock 110 includes a first feedstock portion and asecond feedstock portion. In this embodiment, the composition of thesupply of solid waste feedstock 110 can vary due to varying sources ofwaste material being provided as part of the feedstock. The feedstockanalysis system 120 can collect and analyze respective first and secondsamples from the first and second feedstock portions to determine, viathe at least one physicochemical sensor 122 and at least one spectralsensor 124, at least one physicochemical characteristic and at least onespectral characteristic of the first and second samples of the supply ofsolid waste feedstock 110.

In a specific embodiment provided in FIG. 12 , the control system 150controls an additional process that is implemented by the varioussystems and subsystems of the waste conversion apparatus 100 disclosedherein, and provides control of the systems or subsystems associatedwithin these processes. Referring to FIG. 12 , the at least oneprocessor 152 of the control system 150 is programmed with computerexecutable instructions, as presented in FIG. 12 . The instructionsinclude a first step (1210) of characterizing a composition ofhydrocarbon-containing materials in the first sample of solid wastefeedstock based on the at least one physicochemical characteristic andat least one spectral characteristic of the first sample of solid wastefeedstock, and a second step (1220) of controlling the at least oneplasma forming device 140, based at least on the composition ofhydrocarbon-containing materials in the first sample of solid wastefeedstock, to apply heat at a target temperature profile, for a targettime interval, to the supply of waste feedstock 110 to form the a firstgaseous product. The at least one processor 152 of the control system150 is also programmed with computer executable instructions to, in athird step (1230), characterize a composition of hydrocarbon-containingmaterials in the second sample of solid waste feedstock based on the atleast one physicochemical characteristic and at least one spectralcharacteristic of the second sample of solid waste feedstock, and in afourth step (1240), adjust the at least one plasma forming device 140,based at least on the composition of hydrocarbon-containing materials inthe second sample of solid waste feedstock, to apply heat at a secondtemperature profile, for a second time interval, to the supply of wastefeedstock 110 to form a second gaseous product. In this embodiment atleast one of the second temperature profile and second time interval isdifferent, respectively, from the first temperature profile or the firsttime interval.

In an embodiment, the difference in the at least one of the secondtemperature profile and first temperature profile, or the second timeinterval and the first time interval is determined based on a differencein the compositions of the at least one first gaseous product and the atleast one second gaseous product.

In an embodiment, the difference in the at least one of the secondtemperature profile and first temperature profile, or the second timeinterval and the first time interval is determined based on a differencein the compositions of hydrocarbon-containing materials in the firstportion of solid-waste feedstock and the compositions ofhydrocarbon-containing materials in the second portion of solid wastefeedstock.

In an embodiment of the waste conversion apparatus 100, the controlsystem 150 is connected to the output analysis system that includes theat least gas composition sensor 212 that detects at least onephysicochemical characteristic or at least one spectral characteristicof the at least one gaseous product that is expelled from the reactorchamber 132. In this way, the control system 150 as described hereincontrols at least one process that is implemented by the various systemsand subsystems of the waste conversion apparatus 100 disclosed herein,and provides control of the systems associated within these processes.

Referring to FIG. 13 , the at least one processor 152 of the controlsystem 150 connected to the output analysis system is programmed withcomputer executable instructions to, in a first step (1310) control theat least one plasma forming device 140 to apply heat at a targettemperature profile, for a target time interval, to the supply of wastefeedstock 110 to form the at least one gaseous product having the targetcomposition of hydrocarbon-containing materials, and in a second step(1320), determine an actual composition of the at least one gaseousproduct based on the at least one physicochemical characteristic or atleast one spectral characteristic of the at least one gaseous product,and in a third step (1330) adjust at least one of the target timeinterval and the target temperature profile of heat applied by the atleast one plasma heat forming device based on a detected differencebetween the target composition of the at least one gaseous product andthe actual composition of the at least one gaseous product.

In an embodiment of the waste conversion apparatus 100, the controlsystem 150 is connected to each of the output analysis system 210 andthe feedstock analysis system 120. In this way, the control system 150as described herein controls at least one process that is implemented bythe various systems and subsystems of the waste conversion apparatus 100disclosed herein, and provides control of the systems associated withinthese processes.

Referring to FIG. 14 , the at least one processor 152 of the controlsystem 150 connected to the feedstock analysis system 120 and the outputanalysis system 210 is programmed with computer executable instructionsto, in a first step (1410) characterize a composition ofhydrocarbon-containing materials in the sample of solid waste feedstockbased on the at least one physicochemical characteristic and at leastone spectral characteristic detected by the feedstock analysis system120, in a second step (1420), select a target composition of the atleast one gaseous product based on the characterized composition ofhydrocarbon-containing materials in the sample of solid waste feedstock,and in a third step (1430), control the at least one plasma formingdevice 140, based at least on the composition of hydrocarbon-containingmaterials in the sample of solid waste feedstock, to apply heat at atarget temperature profile, for a target time interval, to the supply ofwaste feedstock 110 to form the at least one gaseous product having thetarget composition. The at least one processor 152 is further programmedwith instructions to, in a fourth step (1440) determine an actualcomposition of the at least one gaseous product based on the at leastone physicochemical characteristic or spectral characteristic of the atleast one gaseous product, and in a fifth step (1450), adjust at leastone of the target time interval and the target temperature profile ofheat applied by the at least one plasma heat forming device based on adetected difference between the target composition of the at least onegaseous product and the actual composition of the at least one gaseousproduct.

In an additional embodiment, the at least one processor 152 isprogrammed with instructions to select or prompt the selection of atarget composition of the at least one gaseous product. In thisembodiment, the step of selecting a target composition of at least onegaseous product that is produced from the supply of solid wastefeedstock 110 can occur at several instances throughout the system.

In embodiment, the step of selecting of a target composition of the atleast one gaseous product is completed after the step of characterizinga composition of hydrocarbon-containing materials in the sample of solidwaste feedstock. In this way, the step of selecting the targetcomposition of the at least one gaseous product is at least partiallybased on the physicochemical characteristic and at least one spectralcharacteristic detected by the feedstock analysis system 120 is used toselect the target

Similarly, the step of selecting of a target composition of the at leastone gaseous product can be completed without performing the step ofcharacterizing a composition of hydrocarbon-containing material in thesample of solid waste feedstock via the feedstock analysis system 120.In this way, the step of selecting the target composition of the atleast one gaseous product is at least partially based on a predeterminedcomposition of the supply of solid waste feedstock 110.

In an additional embodiment, the step of selecting the targetcomposition of the at least one gaseous product is at least partiallybased on a current, market price of at least one composition of the atleast one gaseous product. In this embodiment, the at least oneprocessor 152 of the control system 150 is programmed with computerexecutable instructions to retrieve on a current, market price of atleast one composition of the at least one gaseous product and to aprompt a selection of a target composition of the at least one gaseousproduct.

Post-Processing

In an embodiment such as the embodiment provided in FIG. 16 , the wasteconversion apparatus 100 includes a post-processing system 1610 in fluidconnection with the outlet of the reactor chamber 132. The controlsystem 150 of the waste conversion apparatus 100 is connected to thepost-processing system 1610.

In an embodiment, the at least one sensor element 910 of the controlsubsystem 900 includes at least one post-processing sensor, and the atleast one control element 930 of the control subsystem includes at leastone post-processing control element.

In a further embodiment, the control system 150 controls thepost-processing system 1610 by adjusting the at least onepost-processing control element based on a detected, actual compositionof the at least one gaseous product (as detected by the output analysissystem).

In an alternate embodiment, the control system 150 controls thepost-processing system 1610 by adjusting the at least onepost-processing control element based on a detected temperature of theat least one gaseous product (as detected by the output analysis system210).

In an embodiment, the post-processing system 1610 includes a condenserunit in fluid connection with the outlet conduit of the reactor chamber132, the at least one gaseous product from the reactor chamber 132 beingpassed through the at least one condenser unit to condense and form atleast one liquid product from a portion of the at least one gaseousproduct.

In an embodiment such as the embodiment provided in FIG. 16 , thepost-processing system 1610 includes a heat exchanger unit 1614 in fluidconnection with the outlet conduit 136 of the reactor chamber 132. Theat least one gaseous product is passed through the heat exchanger unit1614 for transferring an amount of excess heat to a working fluid of theheat exchanger unit 1614 such that the working fluid becomes at leastpartially vaporized. In this embodiment, the at least one controlelement of the post-processing system 1610 is any variable component ofthe heat exchanger unit 1614 such as a valve for regulating a flow rateof the working fluid in the heat exchanger unit 1614. In thisembodiment, the post-processing system 1610 may also include a steamturbine for generating electricity, the turbine being in fluidconnection with the heat exchanger unit 1614 such that the working fluidfrom the heat exchanger unit 1614 is fed to the turbine to drive amotion thereof.

In an embodiment such as the embodiment provided in FIG. 16 , thepost-processing system includes a cyclone separator unit 1612. The atleast one gaseous product is passed through the cyclone separator unit1612 to separate out undesirable particulate within the at least onegaseous product. In the specific embodiment provided in FIG. 16 , thecyclone separator unit 1612 is in fluid connection with an outlet of theheat exchanger 1614 that is in fluid connection with the outlet conduit136 of the reactor chamber 132.

In an embodiment such as the embodiment provided in FIG. 17 , thepost-processing system 1610 includes an after-burning unit 1712 in fluidconnection with the outlet conduit 136 of the reactor chamber 132. Theat least one gaseous product is passed through after-burning unit 1712to produce a purified version of the at least one gaseous product.

In an embodiment such as the embodiment provided in FIG. 17 , thepost-processing system 1610 includes a gas cooling and purification unit1714. The at least one gaseous product is passed through the gas coolingpurification unit 1714 to produce a purified version of the at least onegaseous product. In the specific embodiment provided in FIG. 17 , thegas cooling and purification unit 1714 is in fluid connection with anoutlet of the after-burning unit 1712 that is in fluid connection withthe outlet of the reactor chamber 132.

In an additional embodiment, the purified version of the at least onegaseous product is an industrially useful chemical compound such asammonia, hydrogen, or liquid hydrocarbons.

In an embodiment, the computer-executable instructions for implementingthe processes of the control system 150 on the at least one processor152 are provided separately from the control system, for example, on acomputer-readable medium (such as, for example, an optical disk, a harddisk, a USB drive or a media card) or by making them available fordownloading over a communications network, such as the Internet.

In embodiments in which the waste conversion apparatus 100 carries outgasification on the waste feedstock 110, the waste conversion apparatuscould be referred to as a waste gasification apparatus, whether or notother steps such as pyrolysis are also carried out.

The above-described embodiments are intended to be examples of thepresent disclosure and alterations and modifications may be effectedthereto, by those of skill in the art, without departing from the scopeof the disclosure that is defined solely by the claims appended hereto.

What is claimed is:
 1. An apparatus for plasma-based conversion of solidwaste feedstock into hydrocarbon gaseous products, the apparatuscomprising: a reactor vessel defining a reactor chamber including: aninlet; at least one plasma forming device for generating a plasma arctherewithin; and an outlet conduit for expelling at least one gaseousproduct therefrom; a continuous feed-in unit positioned for feeding asupply of solid waste feedstock to the inlet of the reactor chamber, thesupply of solid waste feedstock including a first feedstock portion anda second feedstock portion; a feedstock analysis system positioned tocollect and analyze respective first and second samples from the firstand second feedstock portions, the feedstock analysis system includingat least one physicochemical sensor element for detecting at least onephysicochemical characteristic of the first and second samples, and atleast one spectral sensor element for detecting at least one spectralcharacteristic of the first and second samples; and a control systembeing connected to the feedstock analysis system and the at least oneplasma forming device, and including at least one processor programmedwith computer executable instructions to: characterize a composition ofhydrocarbon-containing materials in the first sample of solid wastefeedstock based on the at least one physicochemical characteristic andat least one spectral characteristic of the first sample of solid wastefeedstock; control the at least one plasma forming device, based atleast on the composition of hydrocarbon-containing materials in thefirst sample of solid waste feedstock, to apply heat at a targettemperature profile, for a target time interval, to the supply ofsolid-waste feedstock to form a first one of the at least one gaseousproduct; characterize a composition of hydrocarbon-containing materialsin the second sample of solid waste feedstock based on the at least onephysicochemical characteristic and at least one spectral characteristicof the second sample of solid waste feedstock; and adjust the at leastone plasma forming device, based at least on the composition ofhydrocarbon-containing materials in the second sample of solid wastefeedstock, to apply heat at a second temperature profile, for a secondtime interval, to the supply of solid-waste feedstock to form a secondone of the at least one gaseous product, at least one of the secondtemperature profile and second time interval being different,respectively, from the first temperature profile or the first timeinterval.
 2. The apparatus according to claim 1, wherein the targettemperature profile and target time interval are determined by thecontrol system based at least on the composition ofhydrocarbon-containing materials characterized by the feedstock analysissystem.
 3. The apparatus according to claim 1, further comprising apre-processing system connected for performing at least onepre-processing process on the supply of solid waste feedstock prior tothe supply of solid waste feedstock being fed to the inlet of thereactor chamber.
 4. The apparatus according to claim 1, wherein adifference in one of the second temperature profile and the firsttemperature profile, or the second time interval and the first timeinterval is determined based on a difference in the compositions of thefirst gaseous product and the second gaseous product.
 5. The apparatusaccording to claim 1, in one of the second temperature profile and thefirst temperature profile, or the second time interval and the firsttime interval is determined based on a difference in the compositions ofhydrocarbon-containing materials in the first portion of solid-wastefeedstock and the compositions of hydrocarbon-containing materials inthe second portion of solid waste feedstock.
 6. The apparatus accordingto claim 1, wherein the at least one plasma-forming device is adirect-current plasma torch.